A recent post by Bob Le Londe makes me want to explore using a router to
spin a 1/32" x 6" cut-off disk. A brand new router will cost less than
the two Barden bearings in my current spindle that is run at 10k with a
1hp 3-phase motor and a flat belt. That spindle started life as a drill
quill 50+ years ago and it's showing it's age and wear...nothing if as
perfect as it should be for quiet, trouble free production use. Thus
the quest for a better solution.

So, what's the best way to mount a wheel with a 7/8" AH to a 1/2"
collet on a router? Something off the shelf?

Tom Gardner wrote:

A recent post by Bob Le Londe makes me want to explore using a router to
spin a 1/32" x 6" cut-off disk. A brand new router will cost less than
the two Barden bearings in my current spindle that is run at 10k with a
1hp 3-phase motor and a flat belt. That spindle started life as a drill
quill 50+ years ago and it's showing it's age and wear...nothing if as
perfect as it should be for quiet, trouble free production use. Thus
the quest for a better solution.

So, what's the best way to mount a wheel with a 7/8" AH to a 1/2"
collet on a router? Something off the shelf?

Will that brand new router last as long as the new set of bearings for
your current spindle? How much labor and down time will each router
replacement cost you vs. rebuilding the current setup and letting it run
a few decades before needing attention again? How about brush
replacement on a router motor vs. none on the current 3ph motor?

On Dec 1, 3:30*am, Tom Gardner mars@tacks wrote:
A recent post by Bob Le Londe makes me want to explore using a router to
spin a 1/32" x *6" cut-off disk. *A brand new router will cost less than
the two Barden bearings in my current spindle that is run at 10k with a
1hp 3-phase motor and a flat belt. That spindle started life as a drill
quill 50+ years ago and it's showing it's age and wear...nothing if as
perfect as it should be for quiet, trouble free production use. *Thus
the quest for a better solution.

* So, what's the best way to mount a wheel with a 7/8" AH to a 1/2"
collet on a router? *Something off the shelf?

Will the cut off wheel take the speed of the router?
Depends on the router I guess.

I made my own router mounts out 1.125 aluminum plate using my original
spindle.

My reasons for going with routers was because I needed more spindle
speed to get decent production out of small end mills. You need to
think about your logistics to determine you want to go this way.
Because I do mostly high speed stuff is the main reason I haven't
worked more diligently on my big mill.

That being said, 10K is pretty fast for a standard mill spindle. You
can do a lot with that.

.... and there is no reason not to fix your spindle AND make a mount
for a high speed router except cost. If you can afford to do both you
should. Your flexibility will be an order of magnitude greater.

"Tom Gardner" mars@tacks wrote in message
...
A recent post by Bob Le Londe makes me want to explore using a router to
spin a 1/32" x 6" cut-off disk. A brand new router will cost less than
the two Barden bearings in my current spindle that is run at 10k with a
1hp 3-phase motor and a flat belt. That spindle started life as a drill
quill 50+ years ago and it's showing it's age and wear...nothing if as
perfect as it should be for quiet, trouble free production use. Thus the
quest for a better solution.

So, what's the best way to mount a wheel with a 7/8" AH to a 1/2" collet
on a router? Something off the shelf?

Make a mandrel if you have a lathe. Even a cheap crappy lathe like mine.
For something like this you don't even have to be too perfect. I was
awfully proud of the first few mandrels I made for special applications, but
now I do it as a matter of course. A 7/8 bolt with a short unthreaded
shoulder will work nicely. If its just right a nut, lock washer, flat
washer to lock the disc in place, but that's not likely to happen. A
threaded coupler half drilled out is more likely. After drilling it out
half way chase it with a tap and substitute for the nut. Turn off the first
half of the threads on your bolt to fit the collet on the router. DO NOT BE
TEMPTED to round the head of the bolt. Leave it hex so you can get a wrench
on it. You will need to turn the back side of the head flat and square to
the shank of the bolt so your disc will set nicely against it.

Or you could see if there is an off the shelf solution. There probably is
one.

On 12/1/2011 6:16 AM, Pete C. wrote:

Tom Gardner wrote:

A recent post by Bob Le Londe makes me want to explore using a router to
spin a 1/32" x 6" cut-off disk. A brand new router will cost less than
the two Barden bearings in my current spindle that is run at 10k with a
1hp 3-phase motor and a flat belt. That spindle started life as a drill
quill 50+ years ago and it's showing it's age and wear...nothing if as
perfect as it should be for quiet, trouble free production use. Thus
the quest for a better solution.

So, what's the best way to mount a wheel with a 7/8" AH to a 1/2"
collet on a router? Something off the shelf?

Will that brand new router last as long as the new set of bearings for
your current spindle? How much labor and down time will each router
replacement cost you vs. rebuilding the current setup and letting it run
a few decades before needing attention again? How about brush
replacement on a router motor vs. none on the current 3ph motor?


I use Hitachi routers for some operations. They are cheap and last
about 6 months. The barden bearings in the spindle last about the same.
We can change out a router in less than 5 minutes, the bearing change
takes about an hour. The routers usually die before they need brushes.

"Tom Gardner" mars@tacks wrote in message
news
On 12/1/2011 6:16 AM, Pete C. wrote:

Tom Gardner wrote:

A recent post by Bob Le Londe makes me want to explore using a router to
spin a 1/32" x 6" cut-off disk. A brand new router will cost less than
the two Barden bearings in my current spindle that is run at 10k with a
1hp 3-phase motor and a flat belt. That spindle started life as a drill
quill 50+ years ago and it's showing it's age and wear...nothing if as
perfect as it should be for quiet, trouble free production use. Thus
the quest for a better solution.

So, what's the best way to mount a wheel with a 7/8" AH to a 1/2"
collet on a router? Something off the shelf?

Will that brand new router last as long as the new set of bearings for
your current spindle? How much labor and down time will each router
replacement cost you vs. rebuilding the current setup and letting it run
a few decades before needing attention again? How about brush
replacement on a router motor vs. none on the current 3ph motor?


I use Hitachi routers for some operations. They are cheap and last about
6 months. The barden bearings in the spindle last about the same. We can
change out a router in less than 5 minutes, the bearing change takes about
an hour. The routers usually die before they need brushes.

How many hours under load? If I got 6 months of 40-50% load time out of a
router I would be absolutely thrilled.

On 12/2/2011 1:22 PM, Bob La Londe wrote:


"Tom Gardner" mars@tacks wrote in message
news
On 12/1/2011 6:16 AM, Pete C. wrote:

Tom Gardner wrote:

A recent post by Bob Le Londe makes me want to explore using a
router to
spin a 1/32" x 6" cut-off disk. A brand new router will cost less than
the two Barden bearings in my current spindle that is run at 10k with a
1hp 3-phase motor and a flat belt. That spindle started life as a drill
quill 50+ years ago and it's showing it's age and wear...nothing if as
perfect as it should be for quiet, trouble free production use. Thus
the quest for a better solution.

So, what's the best way to mount a wheel with a 7/8" AH to a 1/2"
collet on a router? Something off the shelf?

Will that brand new router last as long as the new set of bearings for
your current spindle? How much labor and down time will each router
replacement cost you vs. rebuilding the current setup and letting it run
a few decades before needing attention again? How about brush
replacement on a router motor vs. none on the current 3ph motor?


I use Hitachi routers for some operations. They are cheap and last
about 6 months. The barden bearings in the spindle last about the
same. We can change out a router in less than 5 minutes, the bearing
change takes about an hour. The routers usually die before they need
brushes.

How many hours under load? If I got 6 months of 40-50% load time out of
a router I would be absolutely thrilled.




I would guess about half that. We slot a Beech block 1-1/2" wide x
1/16" to 3/32" deep. We did add a 5hp Powermatic shaper to the job
because it's a LOT quieter and will almost never need parts.